CN113053598A - Lightning protection needle type electric porcelain insulator and preparation method thereof - Google Patents
Lightning protection needle type electric porcelain insulator and preparation method thereof Download PDFInfo
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- CN113053598A CN113053598A CN202110282337.6A CN202110282337A CN113053598A CN 113053598 A CN113053598 A CN 113053598A CN 202110282337 A CN202110282337 A CN 202110282337A CN 113053598 A CN113053598 A CN 113053598A
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B19/00—Apparatus or processes specially adapted for manufacturing insulators or insulating bodies
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B17/00—Insulators or insulating bodies characterised by their form
- H01B17/20—Pin insulators
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B19/00—Apparatus or processes specially adapted for manufacturing insulators or insulating bodies
- H01B19/02—Drying; Impregnating
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B19/00—Apparatus or processes specially adapted for manufacturing insulators or insulating bodies
- H01B19/04—Treating the surfaces, e.g. applying coatings
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract
The invention relates to the technical field of electric porcelain insulators, and provides a lightning protection needle type electric porcelain insulator and a preparation method thereof. The preparation method comprises the following steps: preparing an insulator body, preparing an upper hardware fitting and a lower hardware fitting, and connecting the insulator body with the upper hardware fitting and the lower hardware fitting in a gluing manner; the insulator body comprises the following raw materials in a hydrophobic modification mode: 3-10 parts of modified nylon, 3-10 parts of reinforcing fiber, 2-6 parts of nano silicon dioxide and 2-6 parts of nano titanium dioxide; the preparation of the insulator body comprises the steps of batch ball milling and sectional sintering. The insulator obtained by the invention has excellent lightning protection performance.
Description
Technical Field
The invention relates to the technical field of electric porcelain insulators, in particular to a lightning protection needle type electric porcelain insulator and a preparation method thereof.
Background
The insulator is a special insulating control part used at the joint of a wire tower, a wire receiving part, a substation framework and a line. The insulator is classified into a porcelain insulator, a glass insulator, a composite insulator, and the like according to dielectric materials. At the joint of the wire and the insulator, the insulator is flashover due to the fact that the overvoltage of the direct lightning or the inductive lightning breaks through the insulating layer of the wire, so that electric arcs are burnt at the breakdown position of the insulating layer, and the wire is burnt in a very short time. Meanwhile, the overhead insulated conductor needs to be tested and grounded during maintenance, so that construction safety can be guaranteed.
In the prior art, the existing lightning protection device for the insulated wire and various grounding wire clamps deal with the problem, the grounding wire clamps are respectively arranged on the overhead insulated wire, the insulating layer of the wire needs to be stripped or punctured, so that the wire is damaged in multiple places, the defects of insecurity, high cost, inconvenience in installation and maintenance and the like exist, and the grounding wire clamps bear the larger pulling force of a grounding hook when being arranged on the wire for operation, so that the wire is easy to wear.
Disclosure of Invention
The invention aims to overcome at least one of the defects of the prior art and provides a lightning-proof needle type electric porcelain insulator and a preparation method thereof. The purpose of the invention is realized based on the following technical scheme:
the invention provides a preparation method of a lightning-proof needle type electric porcelain insulator, which comprises the following steps:
s1, preparation of the insulator body:
s11, weighing the following raw materials in parts by weight: 15-22 parts of ginger flushing mud, 15-22 parts of merry pond mud, 12-20 parts of Fujian mud, 12-20 parts of Suzhou mud, 8-15 parts of bauxite, 8-15 parts of Zuoyun soil, 5-12 parts of modified fiber additive and 2-6 parts of barium oxide, wherein the modified fiber additive comprises: 3-10 parts of modified nylon, 3-10 parts of reinforcing fiber, 2-6 parts of nano silicon dioxide and 2-6 parts of nano titanium dioxide; putting the mixture into a ball mill for ball milling until the particle size is 50-200 meshes to obtain a mixture;
s12, weighing the following raw materials in parts by weight: 5-12 parts of bentonite, 3-10 parts of epoxy resin and 0.2-3 parts of coupling agent, adding into the mixture obtained in the step S11, adding a certain amount of water, and performing wet ball milling to obtain uniformly mixed slurry, wherein the fineness is controlled to be 0.4-0.6;
s13, filter pressing and ageing: removing iron from the slurry, dewatering to obtain a mud cake, controlling the water content of the mud cake to be 20-23%, and standing and ageing the mud cake;
s14, pressing and drying: placing the mud cakes in a forming die, digging an internal cavity, trimming the shape of a blank, pressing the blank into a blank, digging a groove on the blank, controlling the water content to be 18-21%, obtaining a formed blank, and drying;
s15, glazing and sintering: spraying glaze slurry on the blank dried in the step S14 to enable the blank to cover a glaze layer, then sintering the blank, and cooling to below 150 ℃ to obtain the product;
s2, preparing an upper hardware fitting and a lower hardware fitting:
s21, processing the weathering steel through a forging machine to obtain crude products of an upper hardware fitting and a lower hardware fitting;
s22, performing anticorrosion treatment on the surfaces of the upper hardware fitting crude products and the lower hardware fitting crude products by a hot-dip galvanizing method;
s23, performing finish machining on the upper hardware fitting and the lower hardware fitting crude products, and eliminating internal and external defects of the upper hardware fitting and the lower hardware fitting to obtain the upper hardware fitting and the lower hardware fitting;
and S3, gluing and connecting the insulator body with the upper hardware fitting and the lower hardware fitting.
The formula widely adopts universal raw materials in most regions, and has wide application range; the variety of raw materials is multiple, and the influence caused by quality fluctuation of a single raw material is reduced; the formula contains silicon dioxide, aluminum oxide and potassium oxide in proper proportion, a large amount of clay or feldspar in the traditional formula is not needed, and the prepared insulator material is good in insulating property and mechanical property, and strong in lightning protection and breakdown resistance. The ginger flushing mud, the mercuric pond mud, the Fujian mud and the Suzhou mud are main components for forming a glass network in the insulator, and are beneficial to improving the compactness and hardness of the network. Most of the bauxite is aluminum oxide, most of the bauxite exists in the insulator in the form of corundum microcrystal in the sintering process, the hardness of the insulator is directly improved, and a small part of the bauxite is fused into a glass body to reinforce a glass network and further improve the hardness. By adding the modified fiber additive, the electrical property and the mechanical property of the insulator are further improved, and the problems that the traditional insulator is poor in antifouling property and easy to break down after being used for a long time are solved.
The modified nylon has good mechanical property, electric resistance and weather resistance, participates in the formation of a glass network in the firing process, and endows the properties of the modified nylon to an insulator product; the modified nylon can improve the self-cleaning effect of the insulator after hydrophobic modification. The reinforcing fibers can form a net-shaped wrapping structure in the blank, so that not only can the hardness of the insulator be increased, but also the melting temperature of the blank is reduced; and can also utilize it to form the porous structure on the surface of the insulator, make the slip glaze penetrate among them and make the blank of the insulator combine with glaze more firmly; and the temperature resistance and mechanical stress of the insulator can be enhanced, and the mechanical property and the lightning protection breakdown-resistant capability of the insulator are improved. In addition, the reinforcing fiber is hydrophobically modified, so that the surface of the insulator has excellent self-cleaning effect. The nano silicon dioxide can reduce the drying and sintering shrinkage of the blank, reduce the bending deformation, play the role of a skeleton of a glaze surface and improve the mechanical strength of the insulator. The nano silicon dioxide and wollastonite do not generate gas in the melting process and are used as fillers to reduce air holes in the sintering process of the insulator and enhance the mechanical bending strength of the surface of the insulator; the shrinkage rate of the ceramic body can be effectively reduced, the moisture absorption expansion of the ceramic insulator can be reduced, the later-stage dry cracking of the ceramic body can be prevented, the ceramic body has higher mechanical strength and lower dielectric loss, the maturing speed of the sintering process can be accelerated, and the heat loss of unit products is greatly reduced. The titanium dioxide has high melting temperature, does not participate in chemical reaction of components forming the insulator, is only dispersed in the original insulating sublayer as a dispersed phase, further fills gaps in the insulator, increases the mechanical strength and the insulating property of the insulator, and improves the cold resistance and the aging resistance of the insulator. In addition, the titanium dioxide also has photocatalytic performance, so that the surface of the titanium dioxide has excellent self-cleaning effect. In conclusion, the modified fiber additive can greatly improve the antifouling property, the mechanical property and the lightning protection breakdown-resistant capability of the porcelain insulator.
The bentonite can be swelled and dispersed into colloidal clay particles in water, so that the suspension property of the slurry can be improved, the adhesion property of the slurry can be improved, a plurality of inorganic substances in the raw materials are tightly adhered together, the compactness and the tightness of the insulator are improved, and the mechanical impact resistance and the breakdown resistance of the insulator are improved.
The epoxy resin is added into the raw materials, has strong adhesiveness, and can be added into the raw materials to tightly adhere various inorganic substances in the raw materials. The coupling agent has the bridge function to connect the raw materials with each other, and the coupling agent and the epoxy resin have synergistic effect, so that the compactness and the tightness of the material are improved, and the mechanical impact resistance and the breakdown resistance of the material are improved.
Preferably, the preparation method of the modified fiber additive in step S11 includes: adding nano silicon dioxide, nano titanium dioxide and a modifying treatment agent into deionized water, and stirring and dispersing for a period of time to obtain an emulsion; adding the reinforced fiber and the obtained emulsion into an ethanol water solution of trimethylolpropane, heating, ultrasonically treating or heating and stirring, separating to obtain a solid product, and drying to obtain the composite material.
Preferably, the reinforcing fiber in step S11 includes one or more of calcium phosphate fiber, calcium titanate fiber, potassium titanate fiber, silicon carbide fiber, boron nitride fiber, and quartz fiber; the hydrophobic modifier of the modified fiber additive comprises one or more of hexamethyl-dinitrogen silane, dimethyl dichlorosilane, dimethyl silicone, perfluoropolyether, dimethyl siloxane and fluorine-containing siloxane.
Preferably, the coupling agent is one or more of aminopropyltriethoxysilane, glycidoxypropyltrimethoxysilane, methacryloxypropyltrimethoxysilane, thiopropyltrimethoxysilane, vinyltriethoxysilane, vinyltrimethoxysilane, 3-aminopropyltrimethoxysilane, gamma-aminopropyltrimethoxysilane and vinyltris (beta-methoxyethoxy) silane.
Preferably, the wet ball milling conditions in step S12 are: the weight ratio of the total raw materials to water is 1: 0.8-1.5 ℃, the temperature is 40-70 ℃, and the ball milling is carried out for 8-15 h.
Preferably, the drying in the step S14 is drying the formed blank at 60-110 ℃ for 36-72 h.
Preferably, the firing in step S15 is specifically: putting the blank into a kiln, taking the room temperature as an initial temperature, heating to 350-500 ℃ at the speed of 10-20 ℃/h, then heating to 1050-1100 ℃ at the speed of 50-100 ℃/h, preserving heat for 5-10 h, then heating to 1280-1350 ℃ at the speed of 20-50 ℃/h in a reducing atmosphere, and preserving heat for 1-3 h.
Preferably, the average thickness of the surface zincate in step S23 is greater than 86 um.
Preferably, the method of rejecting internal and external defects in step S23 is radiographic inspection and magnetic particle inspection.
The invention provides a lightning-proof needle type electric porcelain insulator which is prepared according to any one of the preparation methods.
The invention can obtain at least one of the following beneficial effects:
1. the formula of the porcelain insulator disclosed by the invention adopts multiple functional raw materials for compounding, so that the compactness and strength of a glass network are favorably improved, the blank of the insulator is combined with a glaze surface more firmly, and the obtained porcelain insulator has excellent electrical property, weather resistance and mechanical property. By adding the modified fiber additive, the antifouling property, the mechanical property and the lightning protection capability of the porcelain insulator can be greatly improved.
2. The raw materials in the insulator formula are mixed and ball-milled in batches to obtain functional slurry; the firing temperature is from low to high, and the ceramic insulator is fully combusted, so that the whole firing system is beneficial to the formation and interaction of cordierite, corundum crystal and mullite crystal structures in the insulator, and the mechanical strength and the electrical performance of the insulator product can be obviously improved; the modified fiber additive, the epoxy resin, the coupling agent and the like can be fully dispersed and distributed in the glass phase, so that a compact network is promoted to be formed, and the lightning protection performance of the insulator is improved. The antifouling property, the lightning protection property and the mechanical property of the insulator obtained by the method are greatly improved.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example 1
A preparation method of a lightning protection needle type electric porcelain insulator comprises the following steps:
1. preparing an insulator body:
1) preparation of modified fiber additive: adding nano silicon dioxide, nano titanium dioxide and a modifying treatment agent hexamethyl-disilazane (7.5 percent of the total mass of the modified fiber additive) into deionized water, adding a dispersing agent EFKA SL 3034, a defoaming agent Deform 6800 and a wetting agent GSK-582, and stirring and dispersing for 30min to obtain an emulsion; adding calcium phosphate fiber and the obtained emulsion into ethanol water (20% trimethylolpropane, 72% ethanol and 8% water) solution of trimethylolpropane, heating and stirring at 50 deg.C for 30min, separating to obtain solid product, and drying;
2) weighing the following raw materials in parts by weight: 15 parts of ginger flushing mud, 22 parts of merry pond mud, 20 parts of Fujian mud, 12 parts of Suzhou mud, 15 parts of bauxite, 8 parts of Zuoyun soil, 5 parts of modified fiber additive and 2 parts of barium oxide, wherein the modified fiber additive comprises 3 parts of modified nylon, 10 parts of calcium phosphate fiber, 2 parts of nano silicon dioxide and 2 parts of nano titanium dioxide; putting the mixture into a ball mill for ball milling until the particle size is 50 meshes to obtain a mixture;
3) weighing the following raw materials in parts by weight: 5 parts of bentonite, 3 parts of epoxy resin and 0.2 part of coupling agent aminopropyltriethoxysilane, adding the mixture obtained in the step S11, adding a certain amount of water, and performing wet ball milling, wherein the weight ratio of the total raw materials to the water is 1: 0.8, at the temperature of 40 ℃, performing ball milling for 15 hours to obtain uniformly mixed slurry, wherein the fineness is controlled to be 0.4-0.6;
4) and (3) filter pressing and ageing: removing iron from the slurry, dewatering to obtain a mud cake, controlling the water content of the mud cake to be 20-23%, and standing and ageing the mud cake for 15 hours;
5) and (3) green compact drying: placing the mud cakes in a forming die, digging an internal cavity, trimming the shape of a blank, pressing the blank into a blank, digging a groove on the blank, controlling the water content to be 18-21% to obtain a formed blank, and drying the formed blank at 60 ℃ for 72 hours;
6) glazing and firing: spraying glaze slurry on the blank dried in the step S14 to enable the blank to cover a glaze layer, then firing the blank, putting the blank into a kiln, taking the room temperature as the initial temperature, heating to 350 ℃ at the speed of 10 ℃/h, then heating to 1050 ℃ at the speed of 50 ℃/h, preserving heat for 5h, then heating to 1280 ℃ at the speed of 20 ℃/h in a reducing atmosphere, and preserving heat for 1 h; then cooling to below 150 ℃ at the speed of 50 ℃/h to obtain the product;
2. preparing an upper hardware fitting and a lower hardware fitting:
1) processing the weathering steel by a forging machine to obtain crude products of an upper hardware fitting and a lower hardware fitting, wherein the average thickness of surface zinc dipping is more than 86 um;
2) performing anti-corrosion treatment on the surfaces of the crude products of the upper hardware fitting and the lower hardware fitting by a hot-dip galvanizing method;
3) processing glued parts in mounting inner holes of the upper hardware fitting and the lower hardware fitting crude products into saw-teeth shapes, processing end parts of outlet ends of the upper hardware fitting and the lower hardware fitting crude products into circular arc shapes, and eliminating internal and external defects through radiographic inspection and magnetic particle inspection to obtain the upper hardware fitting and the lower hardware fitting;
3. and the insulator body is connected with the upper hardware fitting and the lower hardware fitting in a gluing manner.
Example 2
A preparation method of a lightning protection needle type electric porcelain insulator comprises the following steps:
1. preparing an insulator body:
1) the preparation method of the modified fiber additive is the same as that of example 1, wherein the modified treating agent is dimethyl dichlorosilane, 10 parts of modified nylon, 3 parts of calcium phosphate fiber, 6 parts of nano silicon dioxide and 6 parts of nano titanium dioxide;
2) weighing the following raw materials in parts by weight: 22 parts of ginger sludges, 15 parts of merry pond sludge, 12 parts of Fujian sludge, 20 parts of Suzhou sludge, 8 parts of bauxite, 15 parts of Zuoyun soil, 12 parts of modified fiber additives and 6 parts of barium oxide, and putting the materials into a ball mill for ball milling until the particle size is 200 meshes to obtain a mixture;
3) weighing the following raw materials in parts by weight: 12 parts of bentonite, 10 parts of epoxy resin and 3 parts of glycidyl ether oxypropyl trimethoxy silane as a coupling agent are added into the mixture obtained in the step S11, a certain amount of water is added for wet ball milling, and the weight ratio of the total raw materials to the water is 1: 1.5, ball milling for 8 hours at the temperature of 70 ℃ to obtain uniformly mixed slurry, wherein the fineness is controlled to be 0.4-0.5;
4) and (3) filter pressing and ageing: removing iron from the slurry, dewatering to obtain mud cakes, controlling the water content of the mud cakes to be 21-23%, and standing and ageing the mud cakes for 30 hours;
5) and (3) green compact drying: placing the mud cakes in a forming die, digging an internal cavity, trimming the shape of a blank, pressing the blank into a blank, digging a groove on the blank, controlling the water content to be 18-20% to obtain a formed blank, and drying the formed blank at 110 ℃ for 36 hours;
6) glazing and firing: spraying glaze slurry on the blank dried in the step S14 to enable the blank to cover a glaze layer, then sintering the blank, putting the blank into a kiln, taking the room temperature as the initial temperature, heating to 500 ℃ at the speed of 20 ℃/h, then heating to 1100 ℃ at the speed of 100 ℃/h, preserving heat for 10h, then heating to 1350 ℃ at the speed of 50 ℃/h in a reducing atmosphere, and preserving heat for 1 h; then cooling to below 150 ℃ at the speed of 100 ℃/h to obtain the product;
2. preparing an upper hardware fitting and a lower hardware fitting:
1) processing the weathering steel by a forging machine to obtain crude products of an upper hardware fitting and a lower hardware fitting, wherein the average thickness of surface zinc dipping is more than 86 um;
2) performing anti-corrosion treatment on the surfaces of the crude products of the upper hardware fitting and the lower hardware fitting by a hot-dip galvanizing method;
3) processing glued parts in mounting inner holes of the upper hardware fitting and the lower hardware fitting crude products into saw-teeth shapes, processing end parts of outlet ends of the upper hardware fitting and the lower hardware fitting crude products into circular arc shapes, and eliminating internal and external defects through radiographic inspection and magnetic particle inspection to obtain the upper hardware fitting and the lower hardware fitting;
3. and the insulator body is connected with the upper hardware fitting and the lower hardware fitting in a gluing manner.
Example 3
A preparation method of a lightning protection needle type electric porcelain insulator comprises the following steps:
1. preparing an insulator body:
1) the preparation method of the modified fiber additive is the same as that in example 1, wherein the modified treating agent is dimethyl silicone, 8 parts of modified nylon, 5 parts of calcium phosphate fiber, 3 parts of nano silicon dioxide and 3 parts of nano titanium dioxide;
2) weighing the following raw materials in parts by weight: 20 parts of ginger sludges, 20 parts of merry pond sludges, 15 parts of Fujian sludges, 15 parts of Suzhou sludges, 10 parts of bauxite, 10 parts of Zuoyun soil, 10 parts of modified fiber additives and 3 parts of barium oxide, and putting the materials into a ball mill for ball milling until the particle size is 100 meshes to obtain a mixture;
3) weighing the following raw materials in parts by weight: 7 parts of bentonite, 8 parts of epoxy resin and 2 parts of coupling agent thiopropyl trimethoxy silane are added into the mixture obtained in the step S11, a certain amount of water is added for wet ball milling, and the weight ratio of the total raw materials to the water is 1: 1, ball milling for 12 hours at the temperature of 50 ℃ to obtain uniformly mixed slurry, wherein the fineness is controlled to be 0.5-0.6;
4) and (3) filter pressing and ageing: removing iron from the slurry, dewatering to obtain a mud cake, controlling the water content of the mud cake to be 20-21%, and standing and ageing the mud cake for 120 hours;
5) and (3) green compact drying: placing the mud cakes in a forming die, digging an internal cavity, trimming the shape of a blank, pressing the blank into a blank, digging a groove on the blank, controlling the water content to be 18-19% to obtain a formed blank, and drying the formed blank at 70 ℃ for 48 hours;
6) glazing and firing: spraying glaze slurry on the blank dried in the step S14 to enable the blank to cover a glaze layer, then firing the blank, putting the blank into a kiln, taking the room temperature as the initial temperature, heating to 400 ℃ at the speed of 15 ℃/h, then heating to 1060 ℃ at the speed of 60 ℃/h, keeping the temperature for 8h, then heating to 1300 ℃ at the speed of 30 ℃/h in a reducing atmosphere, and keeping the temperature for 3 h; then cooling to below 150 ℃ at the speed of 60 ℃/h to obtain the product;
2. preparing an upper hardware fitting and a lower hardware fitting:
1) processing the weathering steel by a forging machine to obtain crude products of an upper hardware fitting and a lower hardware fitting, wherein the average thickness of surface zinc dipping is more than 86 um;
2) performing anti-corrosion treatment on the surfaces of the crude products of the upper hardware fitting and the lower hardware fitting by a hot-dip galvanizing method;
3) processing glued parts in mounting inner holes of the upper hardware fitting and the lower hardware fitting crude products into saw-teeth shapes, processing end parts of outlet ends of the upper hardware fitting and the lower hardware fitting crude products into circular arc shapes, and eliminating internal and external defects through radiographic inspection and magnetic particle inspection to obtain the upper hardware fitting and the lower hardware fitting;
3. and the insulator body is connected with the upper hardware fitting and the lower hardware fitting in a gluing manner.
Example 4
A preparation method of a lightning protection needle type electric porcelain insulator comprises the following steps:
1. preparing an insulator body:
1) the preparation method of the modified fiber additive is the same as that in example 1, wherein the modified treating agent comprises perfluoropolyether, dimethyl siloxane (respectively accounting for 5 percent of the total mass of the modified fiber additive), 5 parts of modified nylon, 5 parts of calcium phosphate fiber, 5 parts of nano-silica and 4 parts of nano-titanium dioxide;
2) weighing the following raw materials in parts by weight: 19 parts of ginger flushing mud, 18 parts of merry pond mud, 18 parts of Fujian mud, 18 parts of Suzhou mud, 13 parts of bauxite, 10 parts of Zuoyun soil, 6 parts of modified fiber additive and 5 parts of barium oxide, and putting the materials into a ball mill for ball milling until the particle size is 150 meshes to obtain a mixture;
3) weighing the following raw materials in parts by weight: 9 parts of bentonite, 5 parts of epoxy resin, 0.5 part of coupling agent vinyl triethoxysilane and 0.5 part of vinyl trimethoxy silane, adding the mixture obtained in the step S11, adding a certain amount of water, and performing wet ball milling, wherein the weight ratio of the total raw materials to the water is 1: 1, ball milling for 10 hours at the temperature of 60 ℃ to obtain uniformly mixed slurry, wherein the fineness is controlled to be 0.4-0.6;
4) and (3) filter pressing and ageing: removing iron from the slurry, dewatering to obtain mud cakes, controlling the water content of the mud cakes to be 22-23%, and standing and ageing the mud cakes for 24 hours;
5) and (3) green compact drying: placing the mud cakes in a forming die, digging an internal cavity, trimming the shape of a blank, pressing the blank into a blank, digging a groove on the blank, controlling the water content to be 20-21% to obtain a formed blank, and drying the formed blank at 100 ℃ for 48 hours;
6) glazing and firing: spraying glaze slurry on the blank dried in the step S14 to enable the blank to cover a glaze layer, then firing the blank, putting the blank into a kiln, taking the room temperature as the initial temperature, heating to 450 ℃ at the speed of 10 ℃/h, then heating to 1080 ℃ at the speed of 80 ℃/h, preserving heat for 6h, then heating to 1320 ℃ at the speed of 40 ℃/h in a reducing atmosphere, and preserving heat for 2 h; then cooling to below 150 ℃ at the speed of 80 ℃/h to obtain the product;
2. preparing an upper hardware fitting and a lower hardware fitting:
1) processing the weathering steel by a forging machine to obtain crude products of an upper hardware fitting and a lower hardware fitting, wherein the average thickness of surface zinc dipping is more than 86 um;
2) performing anti-corrosion treatment on the surfaces of the crude products of the upper hardware fitting and the lower hardware fitting by a hot-dip galvanizing method;
3) processing glued parts in mounting inner holes of the upper hardware fitting and the lower hardware fitting crude products into saw-teeth shapes, processing end parts of outlet ends of the upper hardware fitting and the lower hardware fitting crude products into circular arc shapes, and eliminating internal and external defects through radiographic inspection and magnetic particle inspection to obtain the upper hardware fitting and the lower hardware fitting;
3. and the insulator body is connected with the upper hardware fitting and the lower hardware fitting in a gluing manner.
Example 5
A preparation method of a lightning protection needle type electric porcelain insulator comprises the following steps:
1. preparing an insulator body:
1) the preparation method of the modified fiber additive is the same as that in example 1, wherein the modified treating agent comprises dimethyl siloxane, fluorine-containing siloxane (respectively accounting for 5 percent of the total mass of the modified fiber additive), 6 parts of modified nylon, 7.5 parts of calcium phosphate fiber, 4 parts of nano silicon dioxide and 5 parts of nano titanium dioxide;
2) weighing the following raw materials in parts by weight: 20 parts of ginger sludges, 18 parts of merry pond sludge, 16 parts of Fujian sludge, 15 parts of Suzhou sludge, 12 parts of bauxite, 13 parts of Zuoyun soil, 8 parts of modified fiber additives and 4 parts of barium oxide, and putting the mixture into a ball mill for ball milling until the particle size is 120 meshes to obtain a mixture;
3) weighing the following raw materials in parts by weight: 8 parts of bentonite, 6 parts of epoxy resin, 1 part of coupling agent 3-aminopropyltrimethoxysilane and 0.5 part of gamma-aminopropyltrimethoxysilane, putting the materials into the mixture obtained in the step S11, adding a certain amount of water, and carrying out wet ball milling, wherein the weight ratio of the total raw materials to the water is 1: 1.2, ball milling for 12 hours at the temperature of 60 ℃ to obtain uniformly mixed slurry, wherein the fineness is controlled to be 0.4-0.5;
4) and (3) filter pressing and ageing: removing iron from the slurry, dewatering to obtain mud cakes, controlling the water content of the mud cakes to be 21-22%, and standing and ageing the mud cakes for 24 hours;
5) and (3) green compact drying: placing the mud cakes in a forming die, digging an internal cavity, trimming the shape of a blank, pressing the blank into a blank, digging a groove on the blank, controlling the water content to be 19-20% to obtain a formed blank, and drying the formed blank at 90 ℃ for 48 hours;
6) glazing and firing: spraying glaze slurry on the blank dried in the step S14 to enable the blank to cover a glaze layer, then firing the blank, putting the blank into a kiln, taking the room temperature as the initial temperature, heating to 450 ℃ at the speed of 15 ℃/h, then heating to 1080 ℃ at the speed of 80 ℃/h, preserving heat for 7h, then heating to 1310 ℃ at the speed of 30 ℃/h in a reducing atmosphere, and preserving heat for 2 h; then cooling to below 150 ℃ at the speed of 70 ℃/h to obtain the product;
2. preparing an upper hardware fitting and a lower hardware fitting:
1) processing the weathering steel by a forging machine to obtain crude products of an upper hardware fitting and a lower hardware fitting, wherein the average thickness of surface zinc dipping is more than 86 um;
2) performing anti-corrosion treatment on the surfaces of the crude products of the upper hardware fitting and the lower hardware fitting by a hot-dip galvanizing method;
3) processing glued parts in mounting inner holes of the upper hardware fitting and the lower hardware fitting crude products into saw-teeth shapes, processing end parts of outlet ends of the upper hardware fitting and the lower hardware fitting crude products into circular arc shapes, and eliminating internal and external defects through radiographic inspection and magnetic particle inspection to obtain the upper hardware fitting and the lower hardware fitting;
3. and the insulator body is connected with the upper hardware fitting and the lower hardware fitting in a gluing manner.
Comparative example 1
The remainder of the example 5 was the same as the modified fiber additive.
Comparative example 2
The same procedure as in example 5 was repeated except that the reinforcing fibers, nano-silica and nano-titania were directly added without modification.
Comparative example 3
The reinforcing fibers in the modified fiber additive were removed as in example 5.
Comparative example 4
The nanosilica was removed from the modified fiber additive as in example 5.
Comparative example 5
The nano titanium dioxide in the modified fiber additive was removed as in example 5.
Comparative example 6:
the modified nylon in the modified fiber additive was removed as in example 5.
Comparative example 7
All the raw materials are added into the ball mill at one time for mixing and ball milling, and the rest is the same as the example 5.
Comparative example 8:
the firing was carried out once, and the temperature was raised to 1310 ℃ at a rate of 35 ℃/h under a reducing atmosphere and the temperature was maintained for 8h, and the same procedure as in example 5 was repeated.
Comparative example 9:
the epoxy resin and the coupling agent were removed and the process was the same as in example 5.
The performance of the insulators obtained in examples 1 to 5 and comparative examples 1 to 9 was tested.
Experiment 1: and testing the lightning full-wave surge withstand voltage (peak value).
Experiment 2: artificially simulating pollutant accumulation: the artificial pollutant accumulation test system of the national grid extra-high voltage alternating current test base is used for carrying out experiments, specifically, 50-micrometer sodium chloride and diatomite are used for simulating pollutants, and the rain rate is as follows: 1.0mm/min, and 10min of rain; and (4) manually spraying for 15min, drying for 60min, running for 5d in the environment, and observing the dirt accumulation condition on the surface of the sample.
Experiment 3: the test specimens were subjected to tensile strength testing.
The test results are shown in table 1.
TABLE 1
The test result shows that the porcelain insulator prepared by the formula and the method has excellent lightning protection performance, very obvious antifouling effect and excellent mechanical performance, wherein the effect of the embodiment 5 is optimal. The data in table 1 show that the epoxy resin, the coupling agent, the modified fiber additive, the modification treatment and the reinforcing fiber and the modified nylon in the raw materials have great influence on the lightning protection performance of the insulator, and the change of the firing process of the raw materials also has great influence on the lightning protection performance of the insulator; the modified fiber additive, the modified treatment and reinforcing fiber, the nano titanium dioxide and the modified nylon have great influence on the antifouling performance of the insulator; the tensile strength of the insulators in comparative examples 1 to 9 is smaller than that in example 5, and the influence of the firing process on the tensile strength is the greatest. According to the test data of the comparative examples 1-8, the insulator formula disclosed by the invention has the advantages that various raw materials supplement the manufacturing method, and the obtained insulator has excellent lightning protection performance and good antifouling performance and mechanical performance.
Finally, it should be noted that: although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that modifications may be made to the embodiments or portions thereof without departing from the spirit and scope of the invention.
Claims (10)
1. A preparation method of a lightning protection needle type electric porcelain insulator is characterized by comprising the following steps:
s1, preparation of the insulator body:
s11, weighing the following raw materials in parts by weight: 15-22 parts of ginger flushing mud, 15-22 parts of merry pond mud, 12-20 parts of Fujian mud, 12-20 parts of Suzhou mud, 8-15 parts of bauxite, 8-15 parts of Zuoyun soil, 5-12 parts of modified fiber additive and 2-6 parts of barium oxide, wherein the modified fiber additive comprises: 3-10 parts of modified nylon, 3-10 parts of reinforcing fiber, 2-6 parts of nano silicon dioxide and 2-6 parts of nano titanium dioxide; putting the mixture into a ball mill for ball milling until the particle size is 50-200 meshes to obtain a mixture;
s12, weighing the following raw materials in parts by weight: 5-12 parts of bentonite, 3-10 parts of epoxy resin and 0.2-3 parts of coupling agent, adding into the mixture obtained in the step S11, adding a certain amount of water, and performing wet ball milling to obtain uniformly mixed slurry, wherein the fineness is controlled to be 0.4-0.6;
s13, filter pressing and ageing: removing iron from the slurry, dewatering to obtain a mud cake, controlling the water content of the mud cake to be 20-23%, and standing and ageing the mud cake;
s14, pressing and drying: placing the mud cakes in a forming die, digging an internal cavity, trimming the shape of a blank, pressing the blank into a blank, digging a groove on the blank, controlling the water content to be 18-21%, obtaining a formed blank, and drying;
s15, glazing and sintering: spraying glaze slurry on the blank dried in the step S14 to enable the blank to cover a glaze layer, then sintering the blank, and cooling to below 150 ℃ to obtain the product;
s2, preparing an upper hardware fitting and a lower hardware fitting:
s21, processing the weathering steel through a forging machine to obtain crude products of an upper hardware fitting and a lower hardware fitting;
s22, performing anticorrosion treatment on the surfaces of the upper hardware fitting crude products and the lower hardware fitting crude products by a hot-dip galvanizing method;
s23, performing fine machining on the upper hardware fitting and the lower hardware fitting crude products, and eliminating internal and external defects of the upper hardware fitting and the lower hardware fitting to obtain the upper hardware fitting and the lower hardware fitting;
and S3, gluing and connecting the insulator body with the upper hardware fitting and the lower hardware fitting.
2. The method for preparing the lightning protection needle type electric porcelain insulator according to claim 1, wherein the method for preparing the modified fiber additive in the step S11 comprises the following steps: adding nano silicon dioxide, nano titanium dioxide and a modifying treatment agent into deionized water, and stirring and dispersing for a period of time to obtain an emulsion; adding the reinforced fiber and the obtained emulsion into an ethanol water solution of trimethylolpropane, heating, ultrasonically treating or heating and stirring, separating to obtain a solid product, and drying to obtain the composite material.
3. The method for preparing the lightning protection needle type electrical porcelain insulator according to claim 1, wherein the reinforcing fiber in the step S11 comprises one or more of calcium phosphate fiber, calcium titanate fiber, potassium titanate fiber, silicon carbide fiber, boron nitride fiber and quartz fiber; the hydrophobic modifier of the modified fiber additive comprises one or more of hexamethyl-dinitrogen silane, dimethyl dichlorosilane, dimethyl silicone, perfluoropolyether, dimethyl siloxane and fluorine-containing siloxane.
4. The method of claim 1, wherein the coupling agent is one or more of aminopropyltriethoxysilane, glycidoxypropyltrimethoxysilane, methacryloxypropyltrimethoxysilane, thiopropyltrimethoxysilane, vinyltriethoxysilane, vinyltrimethoxysilane, 3-aminopropyltrimethoxysilane, γ -aminopropyltrimethoxysilane and vinyltris (β -methoxyethoxy) silane.
5. The method for preparing the lightning protection needle type electric porcelain insulator according to claim 1, wherein the wet ball milling conditions in the step S12 are as follows: the weight ratio of the total raw materials to water is 1: 0.8-1.5 ℃, the temperature is 40-70 ℃, and the ball milling is carried out for 8-15 h.
6. The method for preparing the lightning protection needle type electrical porcelain insulator according to claim 1, wherein the drying in the step S14 is that the formed blank is dried for 36-72 hours at 60-110 ℃.
7. The method for preparing the lightning protection needle type electric porcelain insulator according to claim 1, wherein the firing in the step S15 is specifically as follows: putting the blank into a kiln, taking the room temperature as an initial temperature, heating to 350-500 ℃ at the speed of 10-20 ℃/h, then heating to 1050-1100 ℃ at the speed of 50-100 ℃/h, preserving heat for 5-10 h, then heating to 1280-1350 ℃ at the speed of 20-50 ℃/h in a reducing atmosphere, and preserving heat for 1-3 h.
8. The method for preparing the lightning protection needle type electric porcelain insulator according to claim 1, wherein the average thickness of the surface zinc dipping in the step S23 is more than 86 um.
9. The method for preparing the lightning-proof needle-type electric porcelain insulator according to claim 1, wherein the method for removing the internal and external defects in the lightning-proof needle-type electric porcelain insulator in the step S23 is ray inspection and magnetic powder inspection.
10. A lightning-proof needle type electroceramic insulator, characterized by being prepared according to the preparation method of any one of claims 1-9.
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| CN113443892A (en) * | 2021-07-14 | 2021-09-28 | 江西东维电气有限公司 | High-toughness conical suspension type porcelain insulator and preparation method thereof |
| CN113979733A (en) * | 2021-11-16 | 2022-01-28 | 江西凯佳电瓷电器有限公司 | Manufacturing and processing technology of electric power stay insulator |
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